Cabinet system and method of assembling the same

ABSTRACT

A front panel, a pair of side panels, a top panel, and a bottom panel connect to form a cabinet. Optionally, the cabinet includes a rear panel. Front panel includes a pair of master keyways and a pair of grooves. Each of side panels has a side key, a pair of side keyways, and a side notch. Each side key connects with one master keyway. Top panel includes a pair of top keys and a top extender. Each top key connects with one side keyway and top extender connects with one groove. Bottom panel includes a pair of bottom keys and a bottom extender. Each bottom key connects with one side keyway and the bottom extender connects with the other groove.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of application Ser. No. 11/464,987,filed Aug. 16, 2006,which is hereby incorporated by reference.

BACKGROUND

The present disclosure relates to a cabinet system used in kitchens orfurniture design. Specifically, the present disclosure includes a frontpanel, a pair of side panels, a top panel, and a bottom panel that fittogether to form a cabinet. Optionally, the cabinet can include a backpanel or a rear panel.

Several techniques and systems have been developed for manufacturing andassembling cabinets. In a typical system, cabinet components areassembled using mechanical fasteners. In this type of system, often askilled carpenter is required to assemble the cabinets, either in themanufacturing facility or at the final site of installation, for examplea kitchen. The cabinets that are assembled in the manufacturing facilitycan be shipped in the assembled form to the final destination; however,this often requires large amounts of packing materials and shippingcosts to do so. Unassembled cabinets can be shipped to the finaldestination, assembled, and installed at the final site of installation.However, these unassembled cabinets often require a skilled carpenter toassemble the cabinets which requires the homeowner to pay an additionalcost of the carpenter to assemble and install the cabinets.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of a cabinet device shownbeing assembled.

FIG. 2 is a partial perspective view of one embodiment of a cabinetdevice.

FIG. 3 is a front view of one embodiment of a front panel.

FIG. 4 is an end elevational view of the embodiment depicted in FIG. 3,taken along lines 4-4 in FIG. 3 and viewed in the direction of thearrows.

FIG. 5 is a cross-sectional view of the embodiment depicted in FIG. 3,taken along lines 5-5 in FIG. 3 and viewed in the direction of thearrows.

FIG. 6 is a front view of one embodiment of a right side panel.

FIG. 7 is an end elevational view of the embodiment depicted in FIG. 6,taken along lines 7-7 in FIG. 6 and viewed in the direction of thearrows.

FIG. 8 is a cross-sectional view of the embodiment depicted in FIG. 6,taken along lines 8-8 in FIG. 6 and viewed in the direction of thearrows.

FIG. 9 is a front view of another embodiment of a left side panel.

FIG. 10 is an end elevational view of the embodiment depicted in FIG. 9,taken along lines 10-10 in FIG. 9 and viewed in the direction of thearrows.

FIG. 11 is a cross-sectional view of the embodiment depicted in FIG. 9,taken along lines 11-11 in FIG. 9 and viewed in the direction of thearrows.

FIG. 12 is a front view of one embodiment of a top panel.

FIG. 13 is an end elevational view of the embodiment depicted in FIG.12, taken along lines 13-13 in FIG. 12 and viewed in the direction ofthe arrows.

FIG. 14 is a rear view of the embodiment depicted in FIG. 12.

FIG. 15 is a front view of one embodiment of a bottom panel.

FIG. 16 is an end elevational view of the embodiment depicted in FIG.15, taken along lines 16-16 in FIG. 15 and viewed in the direction ofthe arrows.

FIG. 17 is a rear view of the embodiment depicted in FIG. 15.

FIG. 18 is a front view of one embodiment of a rear panel.

FIG. 19 is an end elevational view of the embodiment depicted in FIG.18, taken along lines 19-19 in FIG. 18 and viewed in the direction ofthe arrows.

FIG. 20 is a side elevational view of the embodiment depicted in FIG.17, taken along lines 20-20 in FIG. 18 and viewed in the direction ofthe arrows.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

For the purposes of promoting an understanding of the principles of thedisclosure, reference will now be made to the embodiments illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of theclaims is thereby intended. Any such alterations and furthermodifications in the illustrated device, and any such furtherapplications of the principles as illustrated herein, are contemplatedas would normally occur to one skilled in the art to which thedisclosure relates.

Referring generally to the figures, there are shown embodiments of acabinet device 20. In the illustrated embodiment in FIG. 1, device 20includes a front panel 22, a right side panel 24, a left side panel 26,a top panel 28, and a bottom panel 30. Optionally, cabinet device 20includes a rear panel 32. Front panel 22 (FIG. 2), right side panel 24(FIG. 6), left side panel 26 (FIG. 9), top panel 28 (FIG. 11), bottompanel 30 (FIG. 14), and rear panel 32 (FIG. 17) can be made of variousmaterials such as wood, metal, plastic, or a combination of materials.

In the illustrated embodiment shown in FIG. 3, front panel 22 includesan upper portion 34, an opposite lower portion 36, and a pair of sideportions 38. As illustrated, front panel 22 is a rectangular shape;however, in other embodiments front panel 22 can be a square, trapezoid,oval, or otherwise configured. Each of side portions 38 defines a masterkeyway 40. As illustrated in FIG. 4, master keyway 40 has an L-shape.Upper portion 34 and lower portion 36 each contain a groove 42. Groove42 is rectangular in shape as illustrated in FIG. 5; however, in otherembodiments, groove 42 can be shaped differently such as oval,triangular, polygonal, or otherwise configured. Optionally, front panel22 defines an opening 44. Opening 44 is a rectangular shape; however, inother embodiments, opening 44 is square or otherwise configured.

In the illustrated embodiment in FIGS. 6 and 7, right side panel 24includes an upper portion 50, a lower portion 52, a first side portion54, and a second side portion 56. Right side panel 24 is rectangular inshape; however, in other embodiments right side panel 24 can be asquare, trapezoid, or otherwise configured. Upper portion 50 and lowerportion 52 each define a side keyway 58. Side keyway 58 has an L shapeas illustrated in FIG. 8. In one embodiment, master keyway 40 (FIG. 4)and side keyway 58 (FIG. 8) have substantially similar shapes anddimensions. First side portion 54 includes a side key 60. Side key 60 isrectangular in shape. In other forms, side key 60 can be shapeddifferently such as circular, triangular, polygonal, or otherwiseconfigured. In one form, side key 60 (FIG. 7) and groove 42 (FIG. 5)have substantially similar shapes and dimensions. Second side portion 56includes a side notch 62. Side notch 62 is rectangular in shape. Inother embodiments, side notch 62 is triangular, polygonal, or otherwiseshaped.

FIGS. 9 and 10 show an illustrated embodiment of left side panel 26. Inthe illustrated embodiment, left side panel 26 is similar to right sidepanel 24. In other forms, left side panel 26 can be different than rightside panel 24. Left side panel 26 includes an upper portion 70, a lowerportion 72, a first side portion 74, and a second side portion 76. Leftside panel 26 is rectangular in shape in the illustrated embodiment. Inother embodiments left side panel 26 can be square, trapezoid, oranother shape. Upper portion 70 and lower portion 72 each define a sidekeyway 78. As illustrated in FIG. 11, side keyway 78 has an L shape. Inone embodiment, master keyway 40 (FIG. 4) and side keyway 78 (FIG. 11)have substantially similar shapes and dimensions. In another embodiment,master keyway 40 (FIG. 4), side keyway 58 (FIG. 8), and side keyway 78(FIG. 11) have similar shapes and dimensions. First side portion 74includes a side key 80. Side key 80 is rectangular in shape. In otherforms, side key 80 can be shaped differently such as circular,triangular, polygonal, or otherwise configured. In one form, side key 80(FIG. 10) and groove 42 (FIG. 5) have substantially similar shapes anddimensions. In another form, side key 80, side key 60 (FIG. 7), andgroove 42 (FIG. 5) have similar shapes and dimensions.

In the illustrated embodiment in FIGS. 12, 13, and 14, top panel 28includes an upper portion 90, a lower portion 92, a first side portion94, and a second side portion 96. Top panel 28 is rectangular in shape;however, in other embodiments top panel 28 can be a square, trapezoid,or otherwise configured. Lower portion 92 includes a top extender 98.Top extender 98 is substantially rectangular in shape with a pair ofcurved edges. In one form, top extender 98 is sized to fit within groove42 (see FIGS. 3 and 5) of front panel 22 as discussed below. Both firstside portion 94 and second side portion 96 include a top key 100. Topkey 100 is rectangular in shape or has a U shape; however, in otherforms top key 100 is otherwise configured. In one form top key 100 issubstantially the same cross-sectional size as side key 60 (FIG. 7). Topkey 100 is sized to fit or connect with side keyway 58 as discussedbelow.

In the illustrated embodiment in FIGS. 15, 16, and 17, bottom panel 30includes an upper portion 110, a lower portion 112, a first side portion114, and a second side portion 116. Bottom panel 30 is rectangular inshape; however, in other embodiments bottom panel 28 is otherwiseconfigured. In one form, bottom panel 30 is substantially identical totop panel 28 (see FIG. 12). Lower portion 112 includes a bottom extender118. Bottom extender 118 is rectangular in shape with a pair of curvededges; however, in other forms bottom extender 118 is square orotherwise configured. As illustrated, bottom extender 118 issubstantially similar to top extender 98 (see FIG. 12). In one form,bottom extender 118 is sized to fit within groove 42 of front panel 22(FIGS. 3 and 5). Both first side portion 114 and second side portion 116include a bottom key 120. Bottom key 120 is rectangular in shape or hasa U shape; however, in other forms bottom key 120 is otherwiseconfigured. In one form bottom key 120 is substantially the samecross-sectional size as side key 60 and top key 100 (FIGS. 12 and 13).Bottom key 120 is sized to fit or connect with side keyway 58 (FIGS. 6and 8) as discussed below.

FIGS. 18, 19, and 20 illustrate rear panel 32. Rear panel 32 includes anupper portion 130, a lower portion 132, a first side portion 134, and asecond side portion 136. Rear panel 32 is rectangular in shape. In otherforms, rear panel 32 is substantially the same size as front panel 22(FIG. 3). Upper portion 130 and lower portion 132 each include a slot138. Slot 138 is rectangular in shape; however, in other forms slot 138is square, triangular, or otherwise configured. Slot 138 is sized to fitonto either upper portion 90 of top panel 28 (FIG. 12) or upper portion110 of bottom panel 30 (FIG. 15) as described below. Each of first sideportion 134 and second side portion 136 include a back groove 140. Backgroove 140 is rectangular in shape as illustrated. In other forms, backgroove 140 is square, triangular, or otherwise configured. Optionally,back groove 140 is sized to fit with or contact side notch 62 (FIGS. 6and 7) or side notch 82 (FIGS. 9 and 10) as discussed below. In theillustrated embodiment, slot 138 is rectangular in shape. In otherforms, slot 138 is triangular, polygonal, or otherwise configured.

A cabinet device 20 is formed by assembling together front panel 22,right side panel 24, left side panel 26, top panel 28, and bottom panel30. Optionally, a rear panel 32 is assembled onto cabinet device 20.Right side panel 24 is connected to front panel 22 by sliding side key60 (FIG. 7) into master keyway 40 (FIG. 4) as shown in FIG. 1. Left sidepanel 26 is connected to front panel 22 by sliding side key 80 (FIG. 10)into the other master keyway 40 (FIG. 4) as shown in FIG. 1. Right sidepanel 24 and left side panel 26 are interchangeable to allow eitherpanel to be assembled with either master keyway 40 (FIG. 4) of frontpanel 22. Top panel 28 is connected to front panel 22 by sliding each oftop keys 100 (FIG. 13) into either of side keyway 58 (FIG. 8) of rightside panel 24 or side keyway 78 (FIG. 11) of left side panel 26.Additionally, top extender 98 of top panel 28 fits into groove 42.Bottom panel 30 is connected to front panel 22 by sliding each of bottomkeys 120 (FIG. 16) into the remaining side keyway 58 (FIG. 8) of rightside panel 24 and the remaining side keyway 78 (FIG. 11) of left sidepanel 26. Bottom extender 118 of bottom panel 30 fits into the remaininggroove 42. Top panel 28 and bottom panel 30 are interchangeable suchthat top panel 28 can fit in the location for bottom panel 30 and bottompanel 30 can fit in the location for top panel 28.

Optionally, rear panel 32 fits onto right side panel 24, left side panel26, top panel 28, and bottom panel 30. In particular, one of backgrooves 140 (FIG. 20) fits over or contacts side notch 62 (FIG. 7) ofright side panel 24 and the other of back grooves 140 fits over orcontacts side notch 82 (FIG. 10) of left side panel 26. Additionally,one of slots 138 covers or fits over upper portion 90 (FIG. 12) of toppanel 28 and the other of slots 138 covers or fits over upper portion110 (FIG. 15) of bottom panel 30. Rear panel 32 is configured such thatit is reversible to the extent that either of slots 138 fits over eitherupper portion 90 (FIG. 12) or upper portion 110 (FIG. 15) and either ofback grooves 140 (FIG. 20) fits over either side notch 62 (FIG. 7) orside notch 82 (FIG. 10).

In one embodiment, an adhesive is applied between side key 60 (FIG. 7)and master keyway 40 (FIG. 4) for both of the connections between rightside panel 24 and front panel 22 and between left side panel 26 andfront panel 22. In the same embodiment or another embodiment, adhesiveis applied between each of top keys 100 (FIG. 13), side keyway 58 (FIG.8), and side keyway 78 (FIG. 11), to attach top panel 28 to right sidepanel 24 and left side panel 26. Similarly, adhesive is applied betweeneach of bottom keys 120 (FIG. 16), side keyway 58 (FIG. 8), and sidekeyway 78 (FIG. 11), to attach bottom panel 30 to right side panel 24and left side panel 26. Adhesive can also be applied to top extender 98(FIG. 12) and groove 42 (FIG. 5) to attach top panel 28 to front panel22. Likewise, adhesive can be applied to bottom extender 118 (FIG. 15)and groove 42 (FIG. 5) to attach bottom panel 30 to front panel 22.Optionally, adhesive can be applied to each of slots 138 (FIG. 19),upper portion 90 (FIG. 12), and upper portion 110 (FIG. 15) to attachrear panel 32 to top panel 28 and bottom panel 30. In another form,staples, screws, or other fasteners can be used to attach each of slots138 of rear panel 32 to top panel 28 and bottom panel 30. Alsooptionally, adhesive can be applied to each of back grooves 140 (FIG.20), side notch 62 (FIG. 7), and side notch 82 (FIG. 10) to attach rearpanel 32 to right side panel 24 and left side panel 26. Examples ofadhesive are wood glue, carpenters glue, epoxy, or polyvinyl acetate(PVA), to name a few.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same is to be considered asillustrative and not restrictive in character, it being understood thatall changes and modifications that come within the spirit of theinvention are desired to be protected.

1. A cabinet system comprising: a front panel having a pair of masterkeyways and a pair of grooves; a pair of side panels, each of the sidepanels having a side key, a pair of side keyways, and a side notch, theside key of one of the side panels configured to connect with one of themaster keyways and the side key of the other of the side panelsconfigured to connect with the other one of the master keyways; a toppanel having a pair of top keys and a top extender, each of the top keysconfigured to connect with one of the side keyways, and the top extenderconfigured to connect with one of the pair of grooves; and a bottompanel having a pair of bottom keys and a bottom extender, each of thebottom keys configured to connect with one of the side keyways, and thebottom extender configured to connect with the other of the pair ofgrooves.
 2. The cabinet system of claim 1, further comprising: a rearpanel having a pair of back grooves and a pair of slots, each of theback grooves configured to contact one of the side notches, one of theslots configured to contact the top panel, and the other of the slotsconfigured to contact the bottom panel.
 3. The cabinet system of claim1, wherein the top panel and the bottom panel are interchangeable. 4.The cabinet system of claim 1, wherein each of the master keyways has anL-shape.
 5. The cabinet system of claim 1, wherein each of the side keyshas a U-shape.
 6. The cabinet system of claim 1, wherein each of the topkeys has a U-shape.
 7. The cabinet system of claim 1, wherein the masterkeyways and the side keyways are shaped substantially similar to eachother.
 8. The cabinet system of claim 1, wherein the side keys, the topkeys, and the bottom keys are shaped substantially similar to eachother.
 9. The cabinet system of claim 1, wherein the top panel and thebottom panel are substantially similar to each other.
 10. A method offorming an interlocking cabinet comprising: providing a front panelhaving a pair of master keyways and a pair of grooves; providing a pairof side panels, each of the side panels having a side key, a pair ofside keyways, and a side notch; sliding the side key onto one of themaster keyways to connect one of the side panels with the front panel;sliding the slide key onto the other of the master keyways to connectanother of the side panels with the front panel; providing a top panelhaving a pair of top keys and a top extender; and sliding each of thetop keys onto one of the side keyways to connect the top panel with thepair of side panels.
 11. The method of forming an interlocking cabinetof claim 10, further comprising: placing a rear panel on the pair ofside panels, the top panel and the bottom panel.
 12. The method offorming an interlocking cabinet of claim 10, further comprising:inserting the top extender into one of the pair of grooves.
 13. Themethod of forming an interlocking cabinet of claim 12, furthercomprising: inserting the bottom extender into the other of the pair ofgrooves.
 14. The method of forming an interlocking cabinet of claim 11,wherein the rear panel has a pair of back grooves and a pair of slots;assembling each of the side notches with one of the back grooves toconnect the rear panel to the pair of side panels; and assembling eachof the slots with either the top panel or the bottom panel.
 15. Themethod of forming an interlocking cabinet of claim 10, furthercomprising: attaching both of the side panels to the front panel with anadhesive; attaching the top panel to the pair of side panels with theadhesive; and attaching the bottom panel to the pair of side panels withthe adhesive.
 16. A system of joints for connecting a front panel, apair of side panels, a top panel, and a bottom panel together to form acabinet comprising: a pair of master keyways on the front panel; a sidekey, a pair of side keyways, and a side notch on each of the sidepanels, the side key configured to slide into one of the master keywaysto connect each of the side panels with the front panel; a pair of topkeys on the top panel, each of the top keys configured to slide into oneof the side keyways to connect the top panel with the pair of sidepanels; and a pair of bottom keys on the bottom panel, each of thebottom keys configured to slide into one of the side keyways to connectthe bottom panel with the pair of side panels.
 17. The system of jointsof claim 16, wherein the pair of side keyways are shaped substantiallysimilar to the pair of master keyways.
 18. The system of joints of claim16, wherein the side keys, the top keys, and the bottom keys are shapedsubstantially similar to each other.
 19. The system of joints of claim16, wherein each of the master keyways has an L-shape.
 20. The system ofjoints of claim 16, wherein each of the side keys has a U-shape.
 21. Thesystem of joints of claim 16, wherein each of the top keys has aU-shape.